Removable Footwear Cleat with Cushioning

ABSTRACT

A removable cleat for footwear. The cleat includes a disc with opposing faces. A shoe coupling element is attached to one face of the disc. The other disc face supports a cushioning layer. Traction elements are supported by the cushioning layer. When a user steps on a surface wearing a shoe outfitted with these cleats, the resilience of the cushioning layer at once both lessens the impact of the traction elements on the ground surface and lessens the reaction force on the user&#39;s foot transmitted through the shoe&#39;s outsole. The user&#39;s comfort is thereby enhanced.

This application claims priority from U.S. provisional patentapplication Ser. No. 60/809,323, filed May 30, 2006, entitled “RemovableFootwear Cleat with Cushioning,” which is incorporated herein byreference. This application also claims priority from U.S. provisionalpatent application Ser. No. 60/823,396, filed Aug. 24, 2006, alsoentitled “Removable Footwear Cleat with Cushioning,” which isincorporated herein by reference.

TECHNICAL FIELD

The present invention relates to traction cleats mounted on the bottomof footwear, in particular, on the bottom of athletic footwear.

BACKGROUND

Athletic shoe cleats, in particular golf cleats, have been subject tochanging designs in recent years, to attempt to provide users with avariety of advantages. For many years, a cleat took a simple form of aspike, usually made of metal, attached to the bottom of a shoe. Becausesuch spikes could damage non-athletic surfaces and some athleticsurfaces as well, variations have been made from the simple form. Forexample, UK Patent Application 2,098,457 to Perks discloses surroundinga spike element of a cleat with soft material, to decrease damage doneto surfaces.

SUMMARY OF THE INVENTION

In an embodiment of the invention, a removable cleat for an article offootwear is provided. The cleat includes a disc with opposing faces. Oneface of the disc includes a shoe attachment element for removablyattaching the cleat to the footwear's outsole. A cushioning layerdirectly engages the second face of the disc and a traction elementdirectly engages the cushioning layer, forming a “sandwich.” Thetraction element provides secure footing when installed in footwear. Thecushioning layer affords resilient backing to the traction element,enhancing user comfort. The traction element provides a durable coveringfor at least a portion of the cushioning layer, extending the life ofthe cleat.

In another embodiment of the invention, a removable cleat for a shoe isprovided. The cleat includes a disc with opposing faces. A shoeattachment element is connected to one face of the disc. At least onetraction element directly engages the second face of the disc. Thetraction element includes cushioning material formed in one or morefaces of the traction element. In some embodiments, a face withcushioning material is oriented towards the center of the disc and, inother embodiments, a face with the cushioning material is oriented awayfrom the center of the disc. In further embodiments, the cleat includesa mix of traction elements with each type of face. In yet anotherembodiment, the cleat includes traction elements with cushioningmaterial embedded into more than one face of the traction element.

In another embodiment of the invention, a removable cleat for a shoe isprovided. The cleat includes a disc with opposing faces, with a shoeattachment element connected to one face of the disc. The shoeattachment element removably attaches the cleat to the outsole of theshoe. A cushioning layer includes opposing faces with at least a portionof one face of the cushioning layer directly engaging the surface-facingface of the disc. The cushioning layer further including a debris skirt,such that when the cleat is securely attached to footwear, the debrisskirt substantially prevents debris from moving towards the shoeattachment element. At least one traction element directly engages thesurface-facing face of the cushioning layer and provides secure footingfor the shoe wearer. In some embodiments of the invention, the shape ofthe debris skirt provides additional cushioning to the traction element,when the debris skirt deflects under pressure from the weight of thewearer. The debris skirt may be made with folds, like an accordion orbellows, to provide such cushioning deflection.

In a further embodiment of the invention, a removable cleat for a shoeis provided. The cleat includes a disc with opposing faces. A shoeattachment element is connected to one face of the disc and a tractionelement or traction element assembly also attaches mechanically to thedisc. This method of attaching traction elements to the cleat discprovides a wider choice of materials for the cleat, than is possiblewith conventional bonded connections. The mechanical connection betweentraction element and cleat disc may be provided with a press-fit coupleror a rivet or a connector that rotates to attach the traction element tothe disc. The mechanical connector between traction element and disc maybe provided as a separable component or may be formed as part of atraction element or traction element assembly. In some embodiments, thetraction element is formed with one part of the element attached to thecleat disc and a second part formed as a coupler. The traction elementcan fold over and mate with a corresponding coupler embedded in thecleat disc. The flex of the folded-over traction element provides acushioning effect for the wearer.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing features of the invention will be more readily understoodby reference to the following detailed description, taken with referenceto the accompanying drawings, in which:

FIG. 1 is an exploded view of a removable cleat for footwear, accordingto an embodiment of the invention;

FIG. 2 includes several additional views of the cleat of FIG. 1;

FIG. 3 is a sectional view of a removable cleat for an alternativeembodiment of the invention;

FIG. 4 is another sectional view of the cleat of FIG. 3;

FIG. 5 shows the ground contacting face of the cleat of FIG. 3;

FIGS. 6A-6B illustrate an alternative embodiment of the invention thatincludes cushioning material embedded in traction elements;

FIGS. 6C-6D illustrate another embodiment of the invention that includescushioning material embedded in traction elements;

FIGS. 7A shows a view of the ground-engaging face of a cleat with adebris skirt, in an embodiment of the invention;

FIG. 7B shows a view from the shoe-attachment side of the cleat of FIG.7A;

FIG. 8 shows a cutaway view of a section of the cleat of FIG. 7A;

FIGS. 9A-9B illustrate the reaction of the debris skirt to pressure fromthe adjacent traction element for the cleat of FIG. 7A;

FIG. 10 shows a cleat with a debris skirt that folds, according to anembodiment of the invention;

FIG. 11 shows a cutaway view of a section of the cleat of FIG. 10;

FIG. 12A shows a cleat with a hollow cushioning layer supporting atraction element, according to an embodiment of the invention;

FIG. 12B shows a cutaway view of a section of the cleat of FIG. 12A;

FIG. 13 shows an exploded view of a cleat with a traction element withan integral mechanical coupler, according to an embodiment of theinvention;

FIG. 14 shows a view of the cleat of FIG. 13, assembled;

FIG. 15 shows the cleat of FIG. 13 in a cutaway side view, assembled;

FIG. 16 shows a cleat with a rivet fastener holding folding tractionelements to a cleat disc according to an embodiment of the invention;

FIG. 17 shows a procedure for assembling the cleat of FIG. 16; and

FIG. 18 shows an alternative approach to fastening folding tractionelements to a cleat disc in an embodiment of the invention.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

Definitions. As used in this description and the accompanying claims,the following terms shall have the meanings indicated, unless thecontext otherwise requires:

A “shoe” means any outer covering for a foot including, withoutlimitation, athletic footwear, sandals, boots, and slippers.

A “disc” means any object with opposing, generally planar faces. A disccan include concave portions or convex portions or combinations ofconcave and convex portions. Discs are not limited to circular shapesbut may be, for example, elliptical, triangular, rectangular, or evenirregular shapes, etc.

In various embodiments of the present invention, a removable footwearcleat comprises a shoe attachment portion, a cushioning layer directlyengaging the shoe attachment portion and a traction element assembly,positioned on the cushioning layer. Thus, the cleat forms a “sandwich.”The shoe attachment portion includes a disc with opposing faces. Oneface of the disc includes a shoe attachment element that removablyattaches the cleat to a corresponding element (i.e., receptacle) in ashoe outsole. A second face of the disc supports the cushioning layer.When a user steps on a surface wearing a shoe outfitted with thesecleats, the resilience (i.e., “give”) of the cushioning layer at onceboth lessens the impact of the traction elements on the ground surfaceand lessens the reaction force on the user's foot, as transmittedthrough the shoe's outsole. The user's comfort is thereby enhanced.

In an embodiment of the invention, as shown in the exploded view of FIG.1, a removable cleat 10 consists of a “sandwich” comprising a shoeattachment portion 20, a cushioning layer 30 and a traction elementassembly 40. The shoe attachment portion 20 supports the cushioninglayer 30. The traction element assembly 40 is installed on the surface(or in the surface) of the cushioning layer 30. FIG. 2 shows a plan viewof the cleat of FIG. 1 from the top, along with two sectional views.

Referring to FIG. 1, the shoe attachment portion 20 of the cleatincludes a disc 24 with opposing faces. A male shoe attachment element22 is coupled to a first face of the disc 24. The shoe attachmentelement may be formed according to any design known in the art, such asMacneill Engineering's Q-LOK™ system, which is described in U.S. Pat.No. 5,768,809, which patent is incorporated herein by reference. Thesecond face 26 of the shoe attachment disc 24 includes two or more cleatwrench pin shafts 60, formed typically as hollow cylinders, extendingaway from the disc face 26. These shafts 60 allow a cleat wrench toattach temporarily to the cleat for removably attaching the cleat to ashoe outsole. The user inserts the prongs of a cleat wrench into thewrench pin shafts and applies torque to the wrench to rotate the cleat.Insertion of the shoe attachment element 22 into a matching receptacle(not shown) in the shoe outsole, followed by rotation of the cleat,attaches the cleat to the outsole. These wrench pin shafts extendthrough the cushioning layer of the cleat and through the tractionelement assembly to the surface of the ground-engaging face of thecleat. This construction avoids attaching the cleat wrench to either thetraction element assembly or to the cushioning material. The former islikely to twist as torque is applied by the wrench while the latter istoo soft to transfer torque to the shoe attachment element of the cleateffectively.

In some embodiments of the invention, the second face of the disc 26(i.e. ground-facing face) includes one or more raised portions 61. Thisraised portion 61 is located below the ground-engaging surface of thecleat, when the cleat is complete. In preferred embodiments, this raisedportion may be attached to the center of the ground-facing disc face 26.This raised portion can serve as a wear indicator. When theground-engaging surface (i.e. traction element assembly 40) of the cleathas worn away sufficiently, the wear indicator is exposed as a sign tothe user that the cleat should be replaced. The color of the wearindicator may contrast with the color of traction elements to provide avisible sign to the user that the ground-engaging surface of the cleathas worn away.

The ground-facing face 26 of the cleat disc 24 supports the cushioninglayer 30 of the cleat 10. The cushioning layer provides resilience or“bounce” to the cleat. The cushioning layer may be made of plastic orrubber or another compressible material. In specific embodiments of theinvention, the cushioning layer material preferably ranges in durometerfrom Shore 10A to Shore 50A. In some embodiments, the cushioning layermay take on a regular, convex shape. (See FIG. 5, cushioning layer 40,for example, where the cushioning layer is formed as a disc). In otherembodiments, the cushioning layer may include one or more cutouts ornotches. (See, for example, FIG. 1 where cushioning layer 30 includessix regularly spaced cutouts 42.) The cushioning material can expandinto the space formed by these cutouts 42 as the traction elements abovethe cushioning layer make ground contact, compressing the cushioninglayer. The resilience or bounce provided by the cushioning layer to theshoe attachment element and the traction elements is thereby enhanced.

The traction element assembly 40 of the cleat engages the groundsurface, providing traction for the user. The traction element assemblyof the cleat may be formed with traction elements in a variety of shapesand sizes and with various materials. The traction element assembly 40provides protection for the relatively softer cushioning layer 30, asthe cleat contacts the ground surface. Note that the term “tractionelement assembly” does not imply that all of the traction elements arenecessarily connected in each embodiment of the invention. Some, all ornone of the elements may be connected together in a traction elementassembly.

In the embodiment of the invention shown in FIGS. 1 and 2, the tractionelement assembly consists of six traction teeth 54 connected to acentral hub 51 by individual spokes 52. This traction element assemblystructure allows each traction tooth (and spoke) to flex independentlyof each other tooth and spoke when contacting the ground surface. Thecushioning layer supports and cushions each traction tooth independentlyof each other traction tooth. The cushioning layer provides therestoring force to return the traction tooth and spoke to its originalposition, as a cleat traction tooth leaves the ground surface as thewearer walks. The cushioning layer will flex into the space between thespokes as the spokes move. The traction teeth at the ends of the spokes(which spokes are also known as flex beams) are the primary tractionpoints for the cleat. In various specific embodiments of the invention,these teeth can be of any shape (conical, square, pyramidal,frusto-conical, etc), of any length or height, and may have any shapetip (pointed, blunt, domed, slanted inward, slanted outward, etc). Thenumber of teeth at the end of a spoke is variable and the number ofspokes connected to a disc may number more or less than six. The axis ofeach tooth is preferably oriented at a maximum of 90 degrees to theplane of the cleat (i.e., to the plane of the outsole when installed),or may be substantially less than 90 degrees (e.g., angled toward thecenter of the disc). The hub at the center of the traction elementassembly may be solid or the hub may have an opening to accommodate awear indicator or to allow material in the cushioning layer to flexthrough the opening. In a preferred embodiment of the invention, aplurality of such cleats is provided on a shoe outsole. The independentflexing of the traction elements within a cleat and across the pluralityof cleats supplies traction that adapts well to uneven surfaces.

In embodiments of the invention, the durometer of the traction elementsranges preferably from about Shore 60A to about Shore 98A. In specificembodiments of the invention, the traction elements are formed from athermoplastic material, such as polyurethane. In some embodiments of theinvention, the traction elements are each similar in construction andarranged in a symmetrical pattern around the perimeter of the cushioninglayer. In other embodiments, the traction elements may differ in size,shape, and/or material and may be placed asymmetrically with respect tothe perimeter of the cushioning layer. In each embodiment, thecushioning material provides resilient backing for the harder tractionelement assembly positioned on it when the user puts weight on the cleatthrough the shoe outsole. The disc, being formed of a material that isless resilient than the cushioning layer, provides support for thecushioning layer. The traction element assembly may be formed to fullycover the cushioning layer, providing a high level of protection for thecushioning layer from surface contact, or may cover only a portion ofthe cushioning layer. As described above, the cushioning layer mayinclude notches that allow the cushioning material to expand into thenotches as the traction elements apply pressure to the cushioning layer.These notches can also allow the traction elements to twist fromside-to-side as the cushioning material flexes to fill the notches. Thistraction element twisting action can provide for enhanced traction onuneven surfaces.

In preferred embodiments of the invention, the cushioning layer materialand the traction element assembly material are matched so that thedifference in durometer between the cushioning layer and the tractionelement assembly ranges from about 20 to about 70 points on the Shoredurometer scale. In various embodiments of the invention, the materialsmay be tailored for factors such as the characteristics of the shoewearer or the characteristics of the ground surface. For example, aheavier player may be provided with a cleat with a cushioning layermaterial that is (relatively) harder, coupled with a correspondinglyharder traction element material. A smaller or lighter weight player maybe provided a cleat with corresponding softer elements. As a secondexample, for play on dry, hard, firm ground a cleat with a larger spreadbetween the hardness of the cushioning layer and the traction elementassembly may be provided. For play on wet or soft ground, a cleat with asmaller spread between the hardness of the elements may beadvantageously employed.

FIGS. 3-5 show another illustrative embodiment of the invention. Thisembodiment is similar to the embodiment shown in FIGS. 1-2, except thatthe cushioning layer is formed as a disc without notches. (A commonnumbering scheme is used for the features in FIGS. 3-5 and in FIGS.1-2).

In another embodiment of the invention, as shown in FIGS. 6A and 6B, acleat includes traction elements (110, 115) connected directly to thesecond face (ground-engaging face) 120 of a shoe attachment portion disc120. FIG. 6A is a perspective view of the ground-engaging face of thecleat. The cushioning material 125 is inserted into slots formed in aface of traction elements 110. This face of the traction element facesthe center of the ground-facing face 120 of the disc. FIG. 6B shows atraction element 110 in cross section with the cushioning material 125on the traction element face. The elastic nature of the cushioningmaterial provides a restoring force as a traction tooth compresses thecushioning material under the weight of a user. Likewise, if thetraction element 110 is twisted away from the center of the cleat disc,the elasticity of the cushioning material will provide a restoringforce, tending to return the traction element to its upright position.

In a further related embodiment, as shown in FIGS. 6C and 6D, a cleat200 includes traction elements (210, 215) connected directly to thesecond face (ground-facing face) of a shoe attachment portion disc (notshown). Traction elements 210 include cushioning material 225 insertedinto slots formed in the face of traction elements 210, as shown in FIG.6D. This face of the traction element faces away from the center of theground-facing face of the cleat disc. The elastic nature of thecushioning material provides a restoring force as the traction teethcompress the cushioning material under the weight of a user. Likewise,if the traction element 210 is twisted inward toward the center of thecleat, the elasticity of the cushioning material will provide arestoring force, tending to return the traction element to its originalorientation.

In other embodiments of the invention, a traction element may beprovided with the cushioning material embedded into any face of thetraction element. Further, a traction element may have cushioningmaterial embedded into more than one face of the element. For example, atraction element may have cushioning material embedded into two faces ofthe element with one face oriented towards the center of the cleat discand another face oriented away from the center of the disc. The tractionelements for a cleat may be all of a common type or may include any mixand placement of traction elements with different patterns of cushioningmaterial in traction element faces.

Debris Skirt

In other embodiments of the invention, a removable footwear cleatincludes a cushioning layer with a debris skirt. The debris skirtprevents dirt, grass and other material from entering and clogging thespace between the cleat and outsole of a shoe. The cleat comprises ashoe attachment portion; a cushioning layer directly engaging the shoeattachment portion; and a traction element assembly, positioned on thecushioning layer. The shoe attachment portion includes a disc withopposing faces. One face of the disc includes a shoe attachment elementthat removably attaches the cleat to a corresponding element (e.g.,receptacle) in a shoe outsole. The opposing face of the disc supportsthe cushioning layer. The perimeter of the cushioning layer includes adebris skirt. When installed on the shoe, the skirt extends toward theoutsole of the shoe. When the cleat is fully engaged with thereceptacle, the skirt contacts the outsole, forming a barrier to debris.The structure of the cushioning layer between the skirt and the secondface of the disc can allow the debris skirt to deflect when pressurefrom ground contact forces the traction element into the cushioninglayer. Such debris skirt deflection increases the resiliency of thecushioning layer at the layer's perimeter, enhancing user comfort andprotection of the turf surface.

An example of a cleat 700 with a debris skirt is shown in FIG. 7,according to an embodiment of the invention. FIG. 7A shows a perspectiveview of the ground engaging face of the cleat 700. A plurality oftraction elements 704 are connected via spokes to a center hub 751,forming a traction element assembly. The traction element assemblyengages a cushioning layer 706. The cushioning layer includes a skirt708 which extends upwards and typically contacts the shoe outsole, whenthe cleat is installed in the shoe. A cleat wrench can engage pin shafts710 in the ground engaging face of the cleat to install the cleat intothe shoe. FIG. 7B shows a perspective view of the shoe attachmentportion of the cleat 700. The shoe attachment portion includes a disc714 with opposing faces, one face of which is visible in FIG. 7B, and amale shoe attachment element 712. The shoe attachment element 712 isinserted into a receptacle in the shoe outsole and rotated to attach thecleat to the shoe. The shoe attachment face of the disc 714 includes aperimeter 718, which, in this embodiment, is generally circular. Thecushioning layer 706 includes a hollow portion 716 between the discperimeter 718 and debris skirt 708. FIG. 8 shows a cutaway perspectiveview of the structure of the cleat 700 from the ground engaging side ofthe cleat. As shown in FIG. 9, when pressure is applied to a tractionelement 704 by contact with the ground surface, the debris skirt bendsupward toward the shoe. The hollow 716 behind the debris skirt allowsthe portion of the skirt which contacts the outsole to slide outwardlyfrom the disc's center. The debris skirt at once prevents debris frommigrating towards the shoe attachment element of the cleat and providesadditional cushioning to the traction element as the bottom of the skirtslides outwardly.

In a related specific embodiment of the invention, the outer perimeter1006 of the cushioning layer of a cleat 1000 forming the debris skirtmay include folds, like an accordion or bellows, as shown in FIG. 10. Asillustrated in FIG. 11, the folds allow the outer face of the cushioninglayer to resiliently deflect upwards towards the shoe when pressure isapplied to a traction element 1004. The folds permit the face of thecushioning layer to bend upward towards the outsole without deflectingsubstantially outward from the center of the disc.

In another specific embodiment of the invention, as shown in FIG. 12,the cushioning layer of the cleat 1200 may include cutouts such that thecushioning layer is not rotationally symmetrical about the axis of theshoe attachment element (not shown) of the disc 1214. As describedpreviously, this arrangement allows the cushioning material to expandinto the cutouts as pressure is applied to the traction elements 1204and spokes 1252 of the traction element assembly, enhancing thecushioning effect. A cavity 1216 is provided behind the outer perimeter1208 of the cushioning layer 1206. This cavity can trap air whichprovides an additional cushioning effect as pressure is applied to thetraction element above the cavity. The air trapped in the cavity 1216 bythe outsole of the shoe can escape relatively slowly providing anadditional measure of resiliency for the traction element assembly.While three cutouts (and spokes) are shown for this embodiment, anynumber of spokes and cutouts can be employed in various embodiments ofthe invention.

Mechanical Attachment of Traction Elements to Cleat

In other embodiments of the invention, traction elements or a tractionelement assembly are attached mechanically to the shoe attachmentportion of a cleat. The shoe attachment portion of the cleat comprises adisc with opposing faces attached to a shoe attachment element. One faceof the disc supports a cushioning layer between the traction elementassembly and the disc. Mechanical attachment of the traction elements tothe shoe attachment portion of the cleat allows a wider range ofmaterials to be used for cleat components than are possible with abonded coupling.

The traction element assembly may be coupled to the shoe attachmentportion in one of several ways. First, the traction element assembly maybe fabricated as a structure separate from the shoe attachment portion.The assembly may then couple mechanically to the shoe attachment portionwith a fastener. The assembly may include an integral fastener whichattaches to the cleat or a separate fastener, such as a rivet, maycouple the traction element assembly to the cleat. Second, tractionelements forming the assembly may be fabricated as part of the shoeattachment portion disc, typically on the disc's perimeter. Theseelements can then fold over towards the center of the disc. For example,the traction elements can attach to the face of the disc with afastener, such as a rivet, or a portion of the traction element canserve as a coupling element (male or female) mating to the complementaryelement on the face of the disc.

An illustrative embodiment of this aspect of the invention is shown inFIGS. 13 to 15. FIG. 13 is an exploded view of a cleat 1300. Thetraction element assembly 1310 couples a cushioning layer 1320 to theshoe attachment portion 1330 of the cleat. The traction element assembly1310 includes an integral snap-fit coupler 1315. To assemble the cleat,the cushioning layer 1320 is placed on the shoe attachment portion 1330or bonded to it. The snap-fit coupler of the traction element assembly1310 may then be inserted through the hole in the cushioning layer andinto the hole in the center of the shoe attachment portion of the cleat.Thus, a sandwich of the three structures is formed. In other embodimentsof the invention, a variety of coupler element types may be used, as areknown in the art. FIG. 14 shows a perspective view of the assembledcleat 1300 and FIG. 15 shows a cross-sectional view of the cleat. In aspecific embodiment of the invention, the integral coupler can bereplaced with a separate rivet that fits through the traction elementassembly and attaches the traction element assembly 1310 to the disc1330.

In another illustrative embodiment of the invention, as shown in FIG.16, a separate fastener (in this case, a rivet) connects one end of eachtraction element to the shoe attachment portion of a cleat 1600. Thecleat includes a disc 1610 with opposing faces, a traction element array1620, one or more fold-over traction elements 1630, and a rivet 1640.The traction element array 1620 engages the ground-facing face of thedisc 1610. The array 1620 may be bonded to this face of the disc. Asshown in FIG. 17, each traction element 1630 is attached on one end tothe perimeter of the disc 1610, with the other end of the tractionelement free to move. Each traction element 1630 can be folded overtowards the center of the disc 1610. A rivet 1640 can then be insertedinto the center of the disc 1610. This rivet attaches the free end ofeach traction element 1630 to the face of the disc. FIG. 17 illustratesthe operation of folding over the traction element 1630 and attachingthe element to the face of the disc 1610 with a rivet 1640. The flex ofthe traction elements 1630 when it is folded over to the center of thedisc advantageously enhances the wearer's comfort as the cleat impactsthe ground surface. In some embodiments of the invention, cushioningmaterial may be bonded to the disc face over which the traction elementsfold, providing additional resiliency to the flex of the folded-overtraction element.

In another embodiment of this aspect of the invention, as shown in FIG.18, each traction element 1800 includes a coupling element 1810 on thetraction element's free end. The traction element 1800 is folded overand the coupling element 1810 is inserted into a corresponding couplingelement 1840 in the ground-facing face of the disc 1830. The tractionelement 1800 forms a cavity 1850 when the element is folded over andcoupled to the ground-facing face of the disc. Cushioning material maybe placed on the face of the disc so that this material fits into thecavity 1850 formed by the folded-over traction element 1800. Whenpressure from the outsole of the shoe forces the traction surface 1820of the traction element 1800 into the turf as the wearer steps, the flexof the traction element and the resiliency of the cushioning layeradvantageously enhance the wearer's comfort. While a male couplingelement 1810 is shown at the end of the traction element 1800, inspecific embodiments of the invention, the traction element may includea female coupling element at its free end with a corresponding malecoupling element embedded in the disc.

In specific embodiments of the invention, any of the above cleatembodiments may include one or more of the following variations:

The shoe attachment element structure may employ any structure known inthe art, such as a threaded stud, a Q-LOK™ structure, a TRI-LOK™structure, etc.

The durometer of the traction elements may range from about Shore 60A toabout Shore 98A.

The cushioning layer material may range in durometer from about Shore10A to about Shore 50A and may comprise plastic or rubber or anothercompressible material.

The cushioning layer material and the traction element or tractionelement assembly material can be matched so that the difference indurometer between the cushioning layer and the traction element assemblyranges from about 20 to about 70 points on the Shore durometer scale.

The cleat materials may be tailored for factors such as thecharacteristics of the shoe wearer or the characteristics of the groundsurface. For example, a heavier player may be provided with a cleat witha cushioning layer material that is (relatively) harder, coupled with acorrespondingly harder traction element material. A smaller or lighterweight player may be provided a cleat with corresponding softerelements. As a second example, for play on dry, hard, firm ground acleat with a larger spread between the hardness of the cushioning layerand the traction element assembly may be provided. For play on wet orsoft ground, a cleat with a smaller spread between the hardness of theelements may be advantageously employed.

Cleat Fabrication

The cleats described above may be fabricated using conventionaltechniques, as are known in the art, such as injection molding. In onepreferred method of fabricating a cleat, a two-step process is employed.First, one element, either the traction element or the shoe attachmentportion of the cleat, is molded. Then, this first element is used as an“insert” in a two-color and two-injection plastic molding machine. Thissecond operation molds two elements, in two different colors, and bondsthe three elements together. In practice, the single “insert element”may be loaded into the second machine either by hand, or automaticallyby a “pick and place” robotic arm. In a second preferred method, thetraction element and the attachment element are made separately ininjection plastic molding machines, as individual pieces. Then, theseseparate pieces are loaded as inserts into a second machine. In thesecond machine, the third material is injected into the middle, bondingthe cleat together.

Similarly, it is of course apparent that the present invention is notlimited to the detailed description set forth above. Various changes andmodifications of this invention as described will be apparent to thoseskilled in the art without departing from the spirit and scope of thisinvention as defined in the appended clauses.

1. A removable cleat for a shoe for a user, the cleat comprising: a discincluding opposing first and second faces; a shoe attachment elementattached to the first face of the disc; a cushioning layer; and at leastone traction element, wherein the cushioning layer is located betweenthe second face of the disc and the at least one traction element.
 2. Acleat according to claim 1, further including a plurality of cleatwrench attachment structures, the structures attached to the second faceof the disc.
 3. A cleat according to claim 2, wherein the cleat wrenchattachment structures are generally cylindrical and extend through thecushioning layer.
 4. A cleat according to claim 1, wherein thecushioning layer is bonded to the second face of the disc.
 5. A cleataccording to claim 1, wherein the traction element is bonded to thecushioning layer.
 6. A cleat according to claim 1, wherein thecushioning layer includes at least one cutout.
 7. A cleat according toclaim 1 wherein the at least one traction element is positioned tosubstantially prevent the cushioning layer from contacting a groundsurface, when the cleat installed in a shoe.
 8. A cleat according toclaim 1, wherein a plurality of traction elements directly engage thecushioning layer.
 9. A cleat according to claim 1, wherein the secondface of the disc further includes a raised portion to serve as a wearindicator.
 10. A cleat according to claim 9, wherein the raised portionof the disc face differs in color from the at least one tractionelement.
 11. A cleat according to claim 1, wherein the durometer of thecushioning layer ranges from Shore 10A to Shore 50A.
 12. A cleataccording to claim 1, wherein the durometer of the at least one tractionelement is in the range from Shore 60A to Shore 98A.
 13. A cleataccording to claim 1, wherein the difference in durometer of the atleast one traction element and a portion of the cushioning layer rangesfrom about 20 to about 70 on the Shore scale.
 14. A cleat according toclaim 1, wherein the durometer of the cushioning layer is less than thedurometer of the at least one traction element and the durometer of thecushioning layer is less than the durometer of the disc.
 15. A removablecleat according to claim 1, wherein the cushioning layer is moreresilient that both the at least one traction element and the disc. 16.A cleat according to claim 1, wherein the at least one traction elementincludes: a hub, at least one spoke connected to the hub, and aspecified traction element connected to the spoke at a spoke end distalto the hub.
 17. A cleat according to claim 14, wherein the specifiedtraction element connected to the spoke is shaped as a tooth.
 18. Acleat according to claim 14, wherein the specified traction elementconnected to the spoke is generally frusto-conical in shape.
 19. A cleataccording to claim 1, wherein the cushioning layer further includes adebris skirt such that when the cleat is securely attached to footwear,the debris skirt substantially prevents debris from moving towards theshoe attachment element.
 20. A removable cleat according to claim 19,wherein at least a portion of the debris skirt compresses when the cleatis securely attached to footwear.
 21. A removable cleat according toclaim 20, wherein at least a portion of the debris skirt folds when thecleat is securely attached to footwear.
 22. A removable cleat for a shoefor a user, the cleat comprising: a disc including opposing first andsecond faces; a shoe attachment element attached to the first face ofthe disc; and at least one traction element directly engaging the secondface of disc, the second face of the disc including a center, whereinthe traction element includes cushioning material inserted into slotsformed in a face of the at least one traction element.
 23. A cleataccording to claim 22, wherein the face of the at least one tractionelement including cushioning material generally faces the center of thedisc.
 24. A cleat according to claim 22, wherein the face of the atleast one traction element that includes cushioning material generallyfaces away from the center of the disc.
 25. A removable cleat for a shoefor a user, the cleat comprising: a disc including opposing first andsecond faces; a shoe attachment element attached to the first face ofthe disc; an intermediate layer; and at least one traction element,wherein the intermediate layer is located between the second face of thedisc and the at least one traction element and the intermediate layer issofter than both the at least one traction element and the disc.
 26. Aremovable cleat according to claim 25, wherein the intermediate layer ismore resilient that both the at least one traction element and the disc.27. A removable cleat for footwear, the cleat comprising: a discincluding opposing first and second faces; a shoe attachment elementconnected to the first face of the disc; a cushioning layer; a tractionelement for providing traction on a surface; a connector formechanically attaching the traction element to at least one of the discand the shoe attachment element, wherein the cushioning layer is locatedbetween the disc and the at least one traction element.
 28. A removablecleat according to claim 27, wherein the connector is a press-fitcoupler.
 29. A removable cleat according to claim 27, wherein theconnector is a rivet.
 30. A removable cleat according to claim 27,wherein the connector includes a coupler that rotates to attach thetraction element to the disc.
 31. A removable cleat according to claim27, wherein the connector is part of the traction element.
 32. Aremovable cleat according to claim 27, wherein the traction element isfurther attached to the disc with a non-mechanical connection.
 33. Aremovable cleat according to claim 32, wherein the traction elementfolds over between the non-mechanical connection and the mechanicalconnection.
 34. A removable cleat according to claim 32, wherein thetraction element includes a male connector and the disc includes afemale connector.
 35. A removable cleat according to claim 32, whereinthe traction element includes a female connector and the disc includes amale connector.